Methods for preparing functional optical films

ABSTRACT

The disclosure provides post-production methods for functionalization of optical quality films produced by top tier manufactures. The methods disclosed herein allow for the incorporation of different additives into existing films.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. application Ser. No. 16/624,516filed 19 Dec. 2019, which is a national phase application under 35U.S.C. § 371 of International Application No. PCT/EP2018/066986 filed 25Jun. 2018, which claims priority to European Patent Application No.17305791.0 filed 26 Jun. 2017. The entire contents of each of theabove-referenced disclosures is specifically incorporated by referenceherein without disclaimer.

FIELD OF THE INVENTION

The present disclosure relates to methods for the incorporation offunctional additives into existing high quality optical films.

BACKGROUND

Commercial optical-quality films, such as polycarbonate (PC) orcellulose triacetate (TAC), are customarily produced by a film extrusionprocess, in the case of PC, or by a solvent casting processes, in thecase of either PC or TAC]. Films produced by the solvent casting methodare resistant to high temperature and humidity and exhibit high opticaltransparency and isotropy over the visible light region. The solventcasting process includes the steps of preparing a dope solution, castingthe dope solution onto a super-finished stainless steel belt, capturingand recovering the solvent, drying, annealing, stretching, and relaxingthe formed film. A halogenated hydrocarbon solvent like dichloromethaneis typically used for the dope solution, and the solvent is recoveredusing an expensive condensation process. In order to prevent escape ofhalogenated solvent into the atmosphere, the film is dried in anenvironmentally controlled chamber. The aforementioned steps requiremachinery that makes the optical-quality film solvent casting processprohibitively expensive for new entrants into this manufacturingprocess.

Incorporation of film additives typically occurs early during thesolvent casting process. Additives are added to the dope solutionformation stage, prior to the solution casting step. Some films sufferfrom poor color distribution or bleeding out of additives during solventevaporation. Incorporation of film additives after film production mayaddress distribution issues that arise during evaporation. There is aneed in the industry for alternative, lower cost methods forincorporation of functional additives into optical quality films.

SUMMARY

The present disclosure addresses the need to provide functionalizedfilms by combining the optical quality of films produced by top tiermanufactures with the flexibility of incorporation of functionaladditives into existing films. The inventors have found thatincorporation of dyes and other additives into optical films byco-migration with a solvent or by dispersion into extrudable resinsproduce optical quality films with uniform additive distribution andhigh reproducibility. The methods disclosed herein provide high quality,functionalized optical films at a fraction of the cost of alternativemanufacturing processes.

In some aspects, a method for preparing a functionalized optical filmcomprises the steps of providing a first optical polymer film having asmooth surface and an exposed surface opposite the smooth surface,providing a solution comprising a solvent and a solute comprising atleast one functional additive, applying the solution onto one of thesmooth surface or the exposed surface of the first film to form a coatedfirst film surface and, optionally, evaporating at least a portion ofthe solvent. The solution may optionally include at least one resin. Insome aspects, at least a portion of the solute migrates into and becomesembedded below the first film surface. A second film having a smoothsurface and an exposed surface opposite the smooth surface may beapplied onto the coated first film surface to produce a laminate. Eitherthe exposed surface or the smooth surface of the second film may contactthe coated first film surface. The laminate may be incorporated into alarger laminate. The laminate or larger laminate may be formed into acurved wafer. The laminate, larger laminate, or curved wafer may beincorporated into an optical element, such as a lens.

The optical films have two distinct film surfaces, an exposed surfaceand a smooth surface. In some embodiments, the film smooth surface wasformed by contact with a polished surface that transfers its smoothfinish to a molten polymer or dope solution that is in contact with thepolished surface. In some aspects, the polished surface is a polishedbelt, a polished roller, a polished insert, or a polished table.

The smooth finish is transferred to a film made from a molten polymer ordope solution that is in contact with the polished surface. In someaspects, the smooth surface has a surface roughness value Ra that isless than 0.1. In further aspects, the smooth surface has a surfaceroughness value Ra that is less than 0.05. In a particular aspect, thesmooth surface has a surface roughness value Ra that is less than 0.01.The exposed film surface was open for solvent evaporation and exposed tothe evacuation atmosphere. The smoothness of the exposed surface is lessthan that of the smooth surface that was in contact with the superpolished belt. In some aspects, surface roughness Ra of the smoothsurface is less than surface roughness of the exposed surface. In someembodiments, a laminate produced by the above-described method includesinwardly-facing first film and second film exposed surfaces, that is,the first and second film exposed surfaces are contacting the solute,resulting in a laminate with smooth outward-facing surfaces.

In some embodiments, a method for producing a functionalized opticalfilm or laminate comprises the steps of providing a film or laminate,providing a functionalized adhesive comprising an adhesive component andat least one functional additive, and applying the functionalizedadhesive onto the film or laminate surface to form an adhesive-coatedfunctionalized film or laminate. The adhesive may be a solvent-basedadhesive, a water-based adhesive, or a solvent-free adhesive includingbut not limited to non-reactive thermoplastic polyurethanes, reactiveepoxies, and UV curable acrylates. In some embodiments, the adhesive isa low melt temperature cellulose ester resin, such as mono-substitutedor di-substituted cellulose acetate butyrate. The adhesive may beapplied to a film or laminate by a number of methods known to those ofskill in the art, including but not limited to slot die, roll smooth,gravure roll, Mayer rod, knife over roll, comma roll, immersion, beadcoating, curtain coating, flexible blade, dip & squeeze, hotmelt,reverse roll 3 roll pan, reverse roll 3 roll nip, levelon, slot dieunsupported, slot die supported, 5 roll differential, 4 rolldifferential, 3 roll differential reverse, 3 roll flexo in register,offset reverse with applicator, offset forward with applicator, meteringrod, polishing bar, forward gravure, micro gravure, reverse gravure, andreverse gravure pan. In some aspects an adhesive coated onto a releasefilm such as waxed paper, carrier film, or other intermediate materialand may subsequently be transferred from the release film to the targetfilm, laminate, lens, or other substrate. The adhesive-coatedfunctionalized film or laminate may be incorporated into a largerlaminate or an optical element.

In some embodiments, a method for producing an optical article having afunctionalized optical laminate comprises the steps of providing a filmor laminate, providing a functionalized adhesive comprising an adhesivecomponent and at least one functional additive, extruding thefunctionalized adhesive onto a film or laminate surface to form anadhesive-coated functionalized film or laminate, and incorporating theadhesive-coated functionalized film or laminate into an optical article.

In some aspects, a method for producing a functionalized film orlaminate comprises the steps of casting a functionalized solutioncomprising a functional additive, a solvent, and optionally a resin,onto a carrier support film and evaporating at least a portion of thesolvent. The resulting film is then transferred to a film or laminate toproduce a functionalized film or laminate. The carrier support film maybe foil, polycarbonate (PC), polyethylene terephthalate (PET), or othersupport films known those of skill in the art, and preferably includes apolish-finished release surface. The functionalized solution ispreferably cast onto the polish-finished surface of the carrier supportfilm.

In some aspects, an optical article comprising a functionalized opticalfilm is prepared by providing a first film having a smooth surface andan exposed surface opposite the smooth surface, providing a solutioncomprising a solvent and a solute comprising at least one functionaladditive, applying the solution onto one of the smooth surface or theexposed surface of the first film to form a coated first film surface,and optionally, evaporating at least a portion of the solvent. At leasta portion of the solute becomes embedded below the first film surface.The functionalized first film may be incorporated into an opticalarticle. The functionalized first film may be combined with one or moreadditional films and subsequently incorporated into an optical article.

In some embodiments, an optical article comprising a functionalizedoptical laminate is prepared by providing a film or laminate, providinga functionalized adhesive comprising an adhesive component and at leastone functional additive, extruding the functionalized adhesive onto afilm or laminate surface to form an adhesive-coated functionalized filmor laminate, and incorporating the adhesive-coated functionalized filmor laminate into an optical article.

In some aspects, a method for producing an optical element comprises thesteps of casting a functionalized solution comprising a functionaladditive, a solvent, and optionally a resin, onto a carrier support filmand evaporating at least a portion of the solvent. The resulting film isthen transferred to a film or laminate to produce a functionalized filmor laminate. The carrier support film may be foil, polycarbonate (PC),polyethylene terephthalate (PET), or other support films known those ofskill in the art, and preferably includes a polish-finished releasesurface. The functionalized solution is preferably cast onto thepolish-finished surface of the carrier support film. The functionalizedfilm or laminate may then be incorporated into a larger laminate or intoan optical element. The carrier support film may be selected such thatsurface energies of the carrier film and solution are compatible.

Films can include polycarbonate-, acrylic-, nylon-, cellulose-basedfilms, optical films made from (co)polymers or polymer blends used inthe photographic film and digital display device industry including butnot limited to polyamide (nylon), polyvinyl alcohol, cyclic olefin(co)polymers, aliphatic polyesters (e.g., polylactide),polycaprolactone, polyetherimide, polystyrene or, and other opticalfilms known to those of skill in the art. The film thickness may varydepending on the film composition and/or a film's ability to thermoforminto a desired shape. For example, the cellulose-based film triacetatecellulose (TAC) may be used at a preferred thickness ranging from about80 to about 250 μm. A polycarbonate film may be used at a preferredthickness ranging from about 150 to about 350 μm. The thickness of afilm may be adjusted in order to achieve a desired result. For example,a TAC or PC film having a thickness that is outside the preferred rangeabove may be used if the particular application exhibits improvedresults with the selected thickness. A person of skill in the art isable to experiment and modify film thickness such that a desired resultis achieved. Examples of functional additives include dyes, ultravioletlight absorbers, retardation regulators, stabilizers, antioxidants,tints, pigment, light filters, processing aids such as slip agents andrelease agents, plasticizers, (anti-) static dissipating agents,anti-fog additives, gel-formation-prevention aids, anti-blocking agentssuch as silicates, and other specialty additives known to those of skillin the art. Resins that may be used herein include but are not limitedto polycarbonates, polyurethanes, polyamides, cellulose-based resins,olefin copolymers that may have hard block and soft block polymerregions (e.g., cyclic olefin copolymers), ether-ester copolymers, andthermoplastic elastomers (e.g., polyether block copolymers, polyamideblock copolymers). Those skilled in the art are able to select resinshaving desired optical properties (e.g., optical distortions, clarity,toughness, durability, and processability). Resins are provided in anon-film form, e.g., in solution or as a melt.

“Optical article,” according to the disclosure, is defined as atransparent or translucent object through which a person on one side ofthe optical article may visually perceive an object on the oppositeside. Examples of optical articles include sunglasses, fashion lenses,non-prescription and prescription lenses, sport masks, face shields,goggles, and electronic display screens.

Surface roughness may be determined by methods known to those of skillin the art. A non-limiting example of a method for empiricallydetermining surface roughness is profilometry. Profilometry involvesusing a contact or a non-contact profilometer to measure a surfaceprofile and quantify its roughness. One example of a contactprofilometer employs a diamond stylus that contacts a sample and movesacross the sample surface. The sample surface roughness is detected byvertical displacement of the stylus as it travels over the samplesurface. Examples of non-contact profilometers include lasertriangulation, confocal microscopy, low coherence interferometry, anddigital holography. In some aspects, haze correlates with, and is usedto measure a film's surface roughness. Haze is the percentage of lighttransmitted through a film that is deflected more than 2.5° (degrees)from the direction of the incoming beam. Haze causes light passingthrough a film to scatter and results in a cloudy appearance or poorclarity of objects when viewed through the film. Haze can be empiricallydetermined using a hazemeter or a spectrophotemeter. One particularmethod for measuring haze is ASTM D 1003.

Any embodiment of any of the disclosed compositions and/or methods canconsist of or consist essentially of—rather thancomprise/include/contain/have—any of the described elements and/orfeatures and/or steps. Thus, in any of the claims, the term “consistingof” or “consisting essentially of” can be substituted for any of theopen-ended linking verbs recited above, in order to change the scope ofa given claim from what it would otherwise be using the open-endedlinking verb.

The term “substantially” and its variations are defined as being largelybut not necessarily wholly what is specified as understood by one ofordinary skill in the art, and in one non-limiting embodimentsubstantially refers to ranges within 10%, within 5%, within 1%, orwithin 0.5%.

The term “about” or “approximately” or “substantially unchanged” aredefined as being close to as understood by one of ordinary skill in theart, and in one non-limiting embodiment the terms are defined to bewithin 10%, preferably within 5%, more preferably within 1%, and mostpreferably within 0.5%.

The use of the word “a” or “an” when used in conjunction with the term“comprising” in the claims and/or the specification may mean “one,” butit is also consistent with the meaning of “one or more,” “at least one,”and “one or more than one.”

As used in this specification and claim(s), the words “comprising” (andany form of comprising, such as “comprise” and “comprises”), “having”(and any form of having, such as “have” and “has”), “including” (and anyform of including, such as “includes” and “include”) or “containing”(and any form of containing, such as “contains” and “contain”) areinclusive or open-ended and do not exclude additional, unrecitedelements or method steps.

Other objects, features and advantages of the present invention willbecome apparent from the following detailed description. It should beunderstood, however, that the detailed description and the examples,while indicating specific embodiments of the invention, are given by wayof illustration only. Additionally, it is contemplated that changes andmodifications within the spirit and scope of the invention will becomeapparent to those skilled in the art from this detailed description.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 depicts a dual-film laminate whose TAC film layers are bonded bya functionalized adhesive solution. The dual-film laminate issubsequently incorporated into a polar health laminate by combining thedual-film laminate with a light polarizing film/TAC film laminate. Thepolar health laminate is then incorporated into a light polarizing lens.The term ‘polar’ is defined as any film or multi-film structure thatwill either absorb, transmit, scatter, or reflect incident lightvibrations wholly or partially in a planar, circular, or elipticaldirection. Known structures in the art include, but not limited to,iodine or dichroic dye containing stretched films, nano spaced wire gridfilm, and combinations of polarizing and anisotropic retarding films.The physics of polarized light is well understood by those ordinaryskilled in the art.

FIG. 2 depicts a TAC film that has been coated with a functionalizedcoating solution. The resulting functionalized film is incorporated intoa laminate, which is subsequently incorporated into a polar lens.

FIGS. 3A-B depict laminates produced by a solvent-free thermal bondingprocess. In FIG. 3A, a functionalized thermal adhesive composition (Ply2) is applied onto a laminate comprising a polar PVA film (Ply 4) and aTAC film (Ply 5). In FIG. 3B, the functionalized thermal adhesivecomposition (Ply 2) is applied onto a TAC film base layer (Ply 1). Asecond TAC film layer (Ply 3) is then applied onto the adhesive toproduce a dual-TAC film laminate.

FIG. 4 depicts a solvent casting process for applying a functionalizedsolution to a film or laminate whereby a functionalized solution iscoated onto a carrier support film then transferred to a film orlaminate.

DETAILED DESCRIPTION

Various features and advantageous details are explained more fully withreference to the non-limiting embodiments that are illustrated in theaccompanying drawings and detailed in the following description. Itshould be understood, however, that the detailed description and thespecific examples, while indicating embodiments, are given by way ofillustration only, and not by way of limitation. Various substitutions,modifications, additions, and/or rearrangements will be apparent tothose of ordinary skill in the art from this disclosure.

In the following description, numerous specific details are provided toprovide a thorough understanding of the disclosed embodiments. One ofordinary skill in the relevant art will recognize, however, that theinvention may be practiced without one or more of the specific details,or with other methods, components, materials, and so forth. In otherinstances, well-known structures, materials, or operations are not shownor described in detail to avoid obscuring aspects of the invention.

An objective of the present disclosure is to provide high-quality,functionalized ophthalmic films by incorporating one or more additivesinto mass-produced, high optical quality display films. Thefunctionalized films may be incorporated into ophthalmic and planolenses. A variety of different additives may be incorporated into thefilms, including light filters, tints, and other additives. Theadditives may be incorporated into existing films by co-migration with asolvent below the film's surface or by dispersion into extrudableresins. The methods disclosed herein employ high-quality filmsmass-produced by top tier film manufacturers as substrates and usesemi-synthetic methods to produce high-quality functionalized opticalfilms.

The vast majority of high quality optical films that are produced bysolvent-casting methods are intended for display markets. By contrast,optical films manufactured for niche markets, e.g., ophthalmic and planolenses, are produced on a smaller scale. Films produced by incorporatingdyes, tints, or other additives into the dope solution are more costlyand typically lower in quality as compared to mass-produced opticalfilms used in the display industry. The methods disclosed herein employmass-produced, high optical quality display films as scaffolds forincorporating the desired additives in shorter, limited quantityproduction runs.

High optical quality display films have two distinct film surfaces. Thesmoother surface is formed by contact with a highly-polished beltsurface that transfers its smooth finish to the film surface duringsolvent casting. The opposite film surface is formed by exposure to theevacuation atmosphere and solvent evaporation.

The following examples employ cellulose-ester resin films (e.g.,triacetate cellulose, TAC) as examples, but any optical film known tothose of skill in the art may be employed. Films can includepolycarbonate-, acrylic-, nylon-, cellulose-based films, optical filmsmade from (co)polymers or polymer blends used in the photographic filmand digital display device industry including but not limited topolyamide (nylon), polyvinyl alcohol, cyclic olefin (co)polymers,aliphatic polyesters (e.g., polylactide), polycaprolactone,polyetherimide, polystyreneor, and other optical films known to those ofskill in the art. The term “DYE” as used below encompasses anyfunctional additive, including but not limited to dyes, ultravioletlight absorbers, retardation regulators, stabilizers, antioxidants,tints, pigment, light filter, and other specialty additives forincorporation into a film or laminate. The star annotation (e.g., TAC*,DAC*) denotes a resin (triacetate cellulose, diacetate cellulose, or anyother resin type) that was used either in solution, as a melt, or anyincorporable form that is not a film. Some examples below employ anadditional polar polyvinyl alcohol (PVA) film to impart polarity on thelaminate and finished lens, but any other suitable functional film,including but not limited to an optical absorber, a filter, a clearspacer, or a reflector may be used. A polar PVA film is polyvinylalcohol based light polarizer in which a polyvinyl alcohol filmcontaining one or more dichroic dyes and/or iodine/iodide dyes wasstretched during the manufacturing process to impart light polarizingproperties on the film.

EXAMPLES Example 1: Functionalized Films by Film Solvent Bonding

An adhesive solution comprising a functional additive and a solvent isused to bond two films. The adhesive solution may further comprise aresin. The resulting laminate may be incorporated into an opticalarticle, or may be used to build larger laminates, which in turn may beincorporated into an optical article.

In the exemplary laminate depicted in FIG. 1 , a TAC film is employed asthe base layer (Ply 1). An adhesive solution comprising a functionaladditive (DYE), a resin (TAC*), and a solvent is prepared and applied asPly 2 to the TAC film base layer (Ply 1). The adhesive solution ispreferably applied to the non-polished surface of TAC film Ply 1. Atleast a portion of the adhesive solution solvent may be evaporated. Asecond TAC film is then applied as Ply 3 to the adhesive layer. Thenon-polished surface of TAC film Ply 2 is preferably contacted with theadhesive layer to produce a laminate with polished surfaces facingoutward. Using the above notations, the resulting laminate is of theform TAC/DYE+TAC*/TAC.

In an alternative embodiment, an adhesive solution consisting of afunctional additive (DYE) and a solvent is prepared. The adhesivesolution does not include a resin. The adhesive solution is applied tothe non-polished surface of TAC film Ply 1. At least a portion of theadhesive solution solvent may be evaporated. A second TAC film is thenapplied as Ply 3 to the adhesive layer. The films' non-polished surfacesare preferably in contact with the adhesive solution. The resultinglaminate is of the form TAC/DYE/TAC.

Either of the functionalized three-ply laminates created above(TAC/DYE+TAC*/TAC or TAC/DYE/TAC) may be incorporated into largerlaminates. In the exemplary embodiment depicted in FIG. 1 , a polar PVAfilm is laminated onto the three-ply laminate. A subsequent TAC film isthen laminated onto the polar PVA film. Either or both of thesubsequently-applied layers may be incorporated as described above. Thatis, an adhesive solution comprising comprising a functional additive, asolvent, and optionally a resin may be used to incorporate a functionaladditive into one or more of the subsequently-applied layers. In otherembodiments, either or both of the subsequently-applied layers may beincorporated without a functional additive.

Either of the functionalized laminates described above may beincorporated into an optical article using methods known to those ofskill in the art. In some embodiments, a film or laminate is insertedinto a casting mold, a resin is added in front and/or behind film orlaminate, and the resin is cured using increased temperature,ultraviolet light, e-beam, or a different energy source, or by allowingthe resin to self-cure with the passage of time. In further embodiments,a film or laminate is inserted into an injection mold cavity and a resinis injected in front and/or behind the film or laminate. The resin maythen be cured using the methods discussed above. In some aspects, alaminate can be used as a lens without having gone through a conventioncasting or injection molding process, and can be thermoformed and/orsurface ground int an optical article. In further aspects, an adhesivemay be applied to a film or laminate, followed by forming the film orlaminate into a curved wafer which may then be adhered to the surface ofa lens.

Example 2: Functional Films by Solution Coating

A coating solution comprising a functional additive and a solvent isused to coat and at least partially embeb the additive into a filmlayer. The coating solution may further comprise a binder.

A coating solution comprising a functional additive (DYE) a resin(TAC*), and a solvent is prepared. The coating solution is applied ontoa film. At least a portion of the coating solution solvent may beevaporated. In the example depicted in FIG. 2 , the film is a TAC film(Ply 1, TAC base layer). The coating solution (Ply 2) is preferablyapplied onto the non-polished surface of the film. The resulting coatedfilm is of the form TAC/DYE+TAC*.

In an alternative embodiment, a coating solution comprising a functionaladditive (DYE) and a solvent is prepared and applied onto a film. Thecoating solution is preferably applied onto the non-polished surface ofthe film. At least a portion of the coating solution solvent may beevaporated. The resulting coated film is of the form TAC/DYE.

Either of the functionalized films created above (TAC/DYE+TAC* orTAC/DYE) may be incorporated into larger laminates. In the exemplaryembodiment depicted in FIG. 2 , a polar PVA film (Ply 2) is laminatedonto the functionalized film. A subsequent TAC film (Ply 3) is thenlaminated onto the polar PVA film. Either or both of thesubsequently-applied layers may be incorporated as described above. Thatis, an adhesive solution comprising a functional additive, a solvent,and optionally a resin may be used to coat and at least partially embeda functional additive into one or more of the subsequently-appliedlayers. In other embodiments, either or both of the subsequently-appliedlayers may be incorporated without a functional additive.

Either of the functionalized films or laminates described above may beincorporated into a lens using methods known to those of skill in theart, including but not limited to injection molding and thermosetcasting.

Example 3: Functional Film by Solventless Film Thermal Bonding

A solventless thermal adhesive composition comprising a resin and atleast one functional additive is applied onto a film. The film+adhesivecomposition may be incorporated into a laminate.

A functionalized thermal adhesive composition comprising a resin (DAC*)and at least one functional additive (DYE) is prepared. The resin may bea low melt temperature cellulose ester resin, e.g., mono-/di-substitutedcellulose acetate butyrate.

The functionalized thermal adhesive composition is applied onto alaminate. In the embodiment depicted in FIG. 3A, the functionalizedthermal adhesive composition (Ply 2) is applied onto a laminatecomprising a polar PVA film (Ply 4) and a TAC film (Ply 5). Thefunctionalized thermal adhesive composition is applied to the polar PVAfilm of the PVA/TAC laminate, however, the adhesive may be applied tothe TAC film of the laminate. The resulting laminate is of the formDYE+DAC*/PVA-Polar/TAC. The exposed DYE+DAC* layer may be used tothermally bond the laminate to another film or laminate.

In the alternative embodiment depicted in FIG. 3B, the functionalizedthermal adhesive composition is applied onto a base film by meltextrusion. The functionalized thermal adhesive composition (Ply 2) isapplied onto a TAC film base layer (Ply 1). The thickness of the TACfilm base layer is preferably <80 μm. A second TAC film (Ply 3) isapplied and thermally bonded onto the adhesive layer to produce aTAC/DYE+DAC*/TAC laminate. The thickness of the second TAC film ispreferably <80 μm.

Either of the laminates may be incorporated into a larger laminate andmay optionally be incorporated into a lens using methods known to thoseof skill in the art, including injection molding and thermoset casting.

Example 4: Functional Film by Casting on a Carrier Support Film

A functionalized solution comprising a functional additive, a resin, anda solvent is cast onto a carrier support film then transferred to a filmor laminate.

A functionalized solution comprising a functional additive (DYE), aresin (TAC*), and a solvent is prepared. In the embodiment depicted inFIG. 4 , the solution (Ply 1) is coated onto a carrier support film (Ply0). The carrier support film may be foil, polycarbonate (PC),polyethylene terephthalate (PET), or other support films known those ofskill in the art, and preferably includes a polish-finished releasesurface. The functionalized solution is preferably cast onto thepolish-finished surface of the carrier support film.

At least a portion of the functionalized solution solvent is evaporatedand the resulting stand-alone film is then transferred to a film orlaminate. In the embodiment depicted in FIG. 4 , the stand-alone film(Dye Functional TAC*) is transferred to a PVA/TAC laminate. The carriersupport film is then separated to produce a functionalized film orlaminate. The functionalized film or laminate prepared by the methoddescribed above may be incorporated into a larger laminate, orincorporated into a lens using methods known to those of skill in theart, including injection molding, thermoset casting, or by adhesion toother films.

The claims are not to be interpreted as including means-plus- orstep-plus-function limitations, unless such a limitation is explicitlyrecited in a given claim using the phrase(s) “means for” or “step for,”respectively.

1. A method for producing an optical article comprising a functionalizedoptical laminate comprising: (a) providing a film or laminate; (b)providing a functionalized adhesive comprising an adhesive component andat least one functional additive; (c) extruding the functionalizedadhesive onto a film or laminate surface to form an adhesive-coatedfunctionalized film or laminate; and (d) incorporating theadhesive-coated functionalized film or laminate into an optical article.2. The method of claim 1, wherein the film or laminate comprises one ormore optical polymer films.
 3. The method of claim 1, further comprisingthe step of: laminating a second film or laminate onto theadhesive-coated film or laminate produced in step (c) to form a secondfunctionalized laminate.
 4. The method of claim 3, wherein the secondfilm or laminate comprises one or more optical polymer films.
 5. Themethod of claim 1, wherein the at least one functional additivecomprises at least one of a dye, tint, pigment, and light filter.
 6. Themethod of claim 1, wherein the adhesive component comprises a low-melttemperature cellulose resin.
 7. The method of claim 1, wherein at leasta portion of the at least one functional additive co-migrates into thefilm with the solvent and becomes embedded below the optical film orlaminate surface.
 8. The method of claim 1, wherein at least one surfaceof the film or laminate has a surface roughness value Ra that is lessthan 0.1 μm.
 9. An optical article comprising a functionalized opticalfilm prepared by: providing a first film having a smooth surface and anexposed surface opposite the smooth surface; providing a solutioncomprising a solvent, and a solute comprising at least one functionaladditive; applying the solution onto one of the smooth surface or theexposed surface of the first film to form a coated first film surface;and optionally, evaporating at least a portion of the solvent; whereinat least a portion of the solute is embedded below the first filmsurface.
 10. The optical article of claim 9, wherein the smooth surfacehas a surface roughness value Ra that is less than 0.1 μm.
 11. Theoptical article of claim 9, wherein the exposed surface of the firstfilm is non-polished.
 12. The optical article of claim 9, wherein thepreparation of the functionalized optical film comprises incorporatingthe functionalized first film into an ophthalmic lens.
 13. The opticalarticle of claim 9, wherein at least a portion of the solute co-migratesinto the film with the solvent and becomes embedded below the first filmsurface.
 14. The optical article of claim 9, wherein said functionaladditive comprises at least one of a dye, tint, pigment, and lightfilter.
 15. The optical article of claim 9, wherein the solution is afunctionalized adhesive solution.
 16. The optical article of claim 9,wherein the solution comprises a low-melt temperature cellulose resin.17. An optical article comprising a functionalized optical laminateprepared by: providing a film or laminate; providing a functionalizedadhesive comprising an adhesive component, and at least one functionaladditive; extruding the functionalized adhesive onto a film or laminatesurface to form an adhesive-coated functionalized film or laminate; andincorporating the adhesive-coated functionalized film or laminate intoan optical article.
 18. The optical article of claim 17, wherein atleast one surface of the film or laminate has a surface roughness valueRa that is less than 0.1 μm.
 19. The optical article of claim 17,wherein said functional additive comprises at least one of a dye, tint,pigment, and light filter.
 20. The optical article of claim 17, whereinsaid adhesive component comprises a low-melt temperature celluloseresin.